Structural assembly with patterned panel

Abstract

The present disclosure provides a structural assembly including a frame and a plurality of panels. The frame includes a wall that partially defines an interior region. The plurality of panels is at least partially disposed in the interior region and coupled to the frame. The plurality of panels includes a first panel and a second panel coupled to the first panel. The first panel includes a first side edge, a second side edge opposite the first side edge, a first surface, and a second surface opposite the first surface. The first surface and the second surface cooperate to define a first corrugation extending in a first direction between the first side edge and the second side edge. The second panel includes a third surface defining a plurality of recesses and a fourth surface opposite the third surface defining a plurality of protrusions. The plurality of protrusions is complementary to the plurality of recesses.

Description

[0001] introduction This section provides background information relating to this disclosure, which is not necessarily prior art.

[0002] This disclosure relates to a structural component for a vehicle, and a method for manufacturing and assembling the structural component.

[0003] Vehicle structural components provide structural support and mounting locations for other vehicle parts. Improving the strength and structural performance of vehicle parts is advantageous. However, it is also advantageous for automotive or other vehicle parts to be lightweight to improve efficiency. Therefore, it is advantageous for vehicle parts, such as structural components, to exhibit sufficient strength during normal use and energy absorption characteristics under abnormal conditions such as collisions, while minimizing component weight. Summary of the Invention

[0004] This section provides a general overview of this disclosure, rather than a full disclosure of its entire scope or all its features.

[0005] In various aspects, this disclosure provides a structural assembly including a frame and a plurality of panels. The frame includes a wall that at least partially defines an interior region. The plurality of panels are at least partially disposed in the interior region and coupled to the frame. The plurality of panels include a first panel and a second panel coupled to the first panel. The first panel includes a first side and a second side opposite to the first side. The first panel includes a first surface and a second surface opposite to the first surface. The first and second surfaces cooperate to define a first corrugated portion extending in a first direction between the first and second sides. The second panel includes a third surface and a fourth surface opposite to the third surface. The third surface defines a plurality of recesses. The fourth surface defines a plurality of protrusions complementary to the plurality of recesses.

[0006] In one respect, the first corrugated section extends uninterruptedly between the first and second sides.

[0007] In one aspect, multiple recesses and multiple protrusions define a second corrugated portion extending along a second direction.

[0008] In one respect, the first direction is the same as the second direction.

[0009] In one respect, the first direction differs from the second direction.

[0010] In one respect, the structural components are configured to support external loads greater than or equal to approximately 400 kN.

[0011] In one respect, each of the multiple panels has an average thickness of more than or equal to about 0.5 mm and less than or equal to about 5 mm.

[0012] In one aspect, the first corrugated portion includes a recess width greater than or equal to about 5 mm and less than or equal to about 250 mm. The first corrugated portion includes a planar region width greater than or equal to about 5 mm and less than or equal to about 250 mm. The first corrugated portion includes an angle greater than or equal to about 110 degrees and less than or equal to about 160 degrees.

[0013] In one aspect, the plurality of panels also includes a third panel and a fourth panel connected to the third panel. The third and fourth panels are at least partially located in the interior area and connected to the frame.

[0014] In one aspect, the first and second panels cooperate to define a cover. The third and fourth panels cooperate to define a base plate. The cover and the base plate are spaced apart and cooperate with the frame to define an internal compartment.

[0015] In one aspect, the electrochemical device assembly includes structural components and the electrochemical device itself. The electrochemical device is housed within an internal compartment.

[0016] In one aspect, the structural component also includes a first sealant material. The first sealant material is disposed at least partially between the second panel and the frame.

[0017] In one aspect, the structural component also includes a second sealant material. The second sealant material is disposed at least partially between the first panel and the plate.

[0018] In one aspect, the structural component also includes metallic material. The metallic material is disposed at least partially between the first panel and the second panel.

[0019] In one aspect, multiple panels include high-strength steel, high-strength aluminum, or both high-strength steel and high-strength aluminum.

[0020] In one respect, the first panel is constructed as the vehicle floor.

[0021] In various aspects, this disclosure provides a structural assembly including a frame, a plurality of panels, a first plate, and a plurality of fasteners. The frame includes a wall that at least partially defines an interior region. The plurality of panels are at least partially disposed in the interior region and coupled to the frame. The plurality of panels include a first side and a second side opposite to the first side. The first and second sides extend longitudinally in a first direction. The plurality of panels include a first panel and a second panel coupled to the first panel. The first plate includes a first elongated body extending between a first end and a second end. The first elongated body extends in a first direction. At least a portion of the plurality of panels is at least partially disposed between the first plate and the frame. The plurality of fasteners are configured to clamp the first plate to the frame.

[0022] In one aspect, the first plate has an average thickness greater than or equal to about 2 mm and less than or equal to about 10 mm. A first portion of the first plate is attached to at least a portion of a plurality of panels. The first portion has an average dimension greater than or equal to about 25 mm and less than or equal to about 50 mm.

[0023] In one aspect, the structural assembly further includes a second plate and a plurality of fasteners. The second plate includes a second elongated body extending between a third end and a fourth end. The second elongated body extends in a first direction. The first plate is coupled to a plurality of panels at a first side. The second plate is coupled to a plurality of panels at a second side. At least a portion of the plurality of panels is disposed at least partially between the second plate and the frame. The plurality of fasteners are configured to clamp the second plate to the frame.

[0024] In one respect, the first panel extends along approximately 70% of the length of the multiple panels.

[0025] The present invention also includes the following solutions: Option 1. A structural component, comprising: A frame, the frame including walls that at least partially define an interior region; and A plurality of panels, said plurality of panels being at least partially disposed in the internal region and connected to the frame, said plurality of panels including, A first panel includes a first side and a second side opposite to the first side, a first surface and a second surface opposite to the first surface, the first surface and the second surface cooperating to define a first corrugated portion extending in a first direction between the first side and the second side, and A second panel is coupled to the first panel, the second panel including a third surface and a fourth surface opposite to the third surface, the third surface defining a plurality of recesses, and the fourth surface defining a plurality of protrusions complementary to the plurality of recesses.

[0026] Option 2. The structural component according to Option 1, wherein the first corrugated portion extends uninterruptedly between the first side and the second side.

[0027] Option 3. The structural component according to Option 1, wherein the plurality of recesses and the plurality of protrusions define a second corrugated portion extending along a second direction.

[0028] Option 4. The structural component according to Option 3, wherein the first direction is the same as the second direction.

[0029] Option 5. The structural component according to Option 3, wherein the first direction is different from the second direction.

[0030] Option 6. The structural component according to Option 1, wherein the structural component is configured to support an external load greater than or equal to about 400 kN.

[0031] Option 7. The structural assembly according to Option 1, wherein each of the plurality of panels has an average thickness greater than or equal to about 0.5 mm and less than or equal to about 5 mm.

[0032] Option 8. The structural component according to Option 1, wherein the first corrugated portion includes: The indentation width is greater than or equal to approximately 5 mm and less than or equal to approximately 250 mm. A planar region width greater than or equal to approximately 5 mm and less than or equal to approximately 250 mm. Angles greater than or equal to approximately 110 degrees to less than or equal to approximately 160 degrees.

[0033] Option 9. The structural component according to Option 1, wherein the plurality of panels further includes a third panel and a fourth panel connected to the third panel, the third panel and the fourth panel being at least partially disposed in the internal region and connected to the frame.

[0034] Option 10. The structural component according to Option 9, wherein: The first panel and the second panel cooperate to define the cover. The third and fourth panels cooperate to define the base plate, and The cover and the base plate are spaced apart and cooperate with the frame to define internal compartments.

[0035] Option 11. An electrochemical device assembly comprising: The structural components according to scheme 10; and An electrochemical device, wherein the electrochemical device is disposed in the internal compartment.

[0036] Option 12. The structural component according to Option 1 further includes a first sealant material, wherein the first sealant material is at least partially disposed between the second panel and the frame.

[0037] Option 13. The structural component according to Option 12 further includes a second sealant material, wherein the second sealant material is at least partially disposed between the first panel and the plate.

[0038] Option 14. The structural component according to Option 12 further includes a metallic material, wherein the metallic material is at least partially disposed between the first panel and the second panel.

[0039] Option 15. The structural assembly according to Option 1, wherein the plurality of panels comprises high-strength steel, high-strength aluminum, or both high-strength steel and high-strength aluminum.

[0040] Option 16. The structural component according to Option 1, wherein the first panel is configured as a vehicle floor.

[0041] Option 17. A structural component, comprising: A frame, the frame including walls that at least partially define an interior region; A plurality of panels, the plurality of panels being at least partially disposed in the internal region and connected to the frame, the plurality of panels including a first side and a second side opposite to the first side, the first side and the second side extending longitudinally in a first direction, the plurality of panels including a first panel and a second panel connected to the first panel; A first plate, the first plate comprising a first elongated body extending between a first end and a second end, the first elongated body extending in a first direction; and Multiple fasteners, including: At least a portion of the plurality of panels is disposed at least partially between the first panel and the frame, and The plurality of fasteners are configured to clamp the first plate to the frame.

[0042] Option 18. The structural component according to Option 17, wherein: The first plate has an average thickness greater than or equal to about 2 mm and less than or equal to about 10 mm, and A first portion of the first plate is coupled to at least a portion of the plurality of panels, the first portion of the first plate having an average size greater than or equal to about 25 mm and less than or equal to about 50 mm.

[0043] Option 19. The structural assembly according to Option 17 further includes a second plate and a plurality of fasteners, the second plate including a second elongated body extending between a third end and a fourth end, the second elongated body extending in the first direction, wherein: The first plate is connected to the plurality of panels at the first side. The second plate is connected to the plurality of panels at the second side. At least a portion of the plurality of panels are disposed at least partially between the second panel and the frame, and The second plurality of fasteners are configured to clamp the second plate to the frame.

[0044] Option 20. The structural assembly according to Option 17, wherein the first plate extends along approximately 70% of the length of the plurality of panels, which is greater than or equal to that of the first plate.

[0045] Further areas of application will become apparent from the description provided herein. The descriptions and specific examples in this invention are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0046] The accompanying drawings described herein are for illustrative purposes only, for the purposes of selecting embodiments and not all possible implementations, and are not intended to limit the scope of this disclosure.

[0047] Figure 1A It is a perspective view of structural sub-components including a frame and multiple panels according to various aspects of this disclosure; Figure 1B yes Figure 1A An exploded diagram of the structural sub-components; Figure 1C yes Figure 1A structural sub-components along Figure 1A A cross-sectional view taken from line 1C-1C; Figure 1D yes Figure 1C A partial cross-sectional view of the structural sub-component; Figure 1E yes Figure 1A A perspective view of the frame; Figure 1F yes Figure 1E The framework along Figure 1E A cross-sectional view taken from line 1F-1F; Figure 1G yes Figure 1A A perspective view of one of the multiple panels; Figure 1H It is along Figure 1A The line 1H-1H cut Figure 1A Partial cross-sectional views of multiple panels; Figure 1I It is based on all aspects of this disclosure, including Figure 1A A partial cross-sectional view of the structural components of the sub-components; Figure 1J It is based on all aspects of this disclosure, including Figure 1A A partial cross-sectional view of another structural component of the sub-component; Figure 1K It is based on all aspects of this disclosure, including Figure 1A A partial cross-sectional view of the rechargeable energy storage system (“RESS”) component of the sub-component; Figure 2A It is a perspective view of another framework based on various aspects of this disclosure; Figure 2B This is a perspective view of yet another framework according to various aspects of the present invention; Figure 2C This is a partial cross-sectional view, which is part of another framework according to various aspects of the invention; Figure 2D This is a partial cross-sectional view, which is part of another framework according to various aspects of the invention; Figure 3A This is a perspective view of another panel according to various aspects of this disclosure; Figure 3B This is a perspective view of another panel based on various aspects of this disclosure; Figure 3C This is a perspective view of another panel based on various aspects of this disclosure; Figure 3D This is a perspective view of another panel based on various aspects of this disclosure; Figure 3E This is a perspective view of another panel based on various aspects of this disclosure; Figure 4A This is a partial schematic top view of structural components including fluid discharge according to various aspects of this disclosure; Figure 4B yes Figure 4A Structural components along Figure 4A A partial cross-sectional view taken from line 4B-4B; Figure 5 This is a partial cross-sectional view of a structural component including a barrier material according to various aspects of this disclosure; Figure 6A This is a schematic top view of the RESS components according to various aspects of this disclosure; Figure 6B This is a schematic top view of another RESS component according to various aspects of this disclosure; Figure 6C This is a schematic top view of yet another RESS component according to various aspects of this disclosure; Figure 6D This is a schematic top view of yet another RESS component according to various aspects of this disclosure; Figure 7 It is a flowchart illustrating a method for manufacturing structural components according to various aspects of this disclosure; Figure 8A It is an exploded view of structural sub-assemblies including frames, multiple panels and multiple plates according to various aspects of this disclosure; Figure 8B yes Figure 8A structural sub-components along Figure 8A A partial cross-sectional view taken from line 8B-8B; Figure 9A This is a partial cross-sectional view of a structural component including a sealant material according to various aspects of this disclosure; Figure 9B This is a partial cross-sectional view of another structural component, including the sealant material, according to various aspects of this disclosure; Figure 9C This is a partial cross-sectional view of another structural component, including the sealant material, according to various aspects of this disclosure; and Figure 9D This is a partial cross-sectional view of another structural component, including a sealant material, according to various aspects of this disclosure.

[0048] In the several views of the accompanying drawings, the corresponding reference numerals indicate the corresponding parts. Detailed Implementation

[0049] Example embodiments are provided to make this disclosure thorough and to fully convey the scope to those skilled in the art. Numerous specific details, such as examples of specific components, parts, apparatuses, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required, exemplary embodiments may be implemented in many different forms, and none should be construed as limiting the scope of this disclosure. In some example embodiments, well-known processes, well-known apparatus structures, and well-known technologies are not described in detail.

[0050] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are also intended to include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and thus specify the presence of the stated features, elements, components, steps, integrals, operations, and / or parts, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, parts, and / or groups thereof. While the open-ended term “comprising” should be understood as a non-limiting term used to describe and claim the various embodiments set forth herein, in some aspects it may alternatively be understood as a more restrictive and limiting term, such as “composed of” or “substantially composed of.” Therefore, for any given embodiment that describes components, materials, parts, elements, features, integrals, operations, and / or process steps, this disclosure also specifically includes embodiments that consist of or substantially consist of those described components, materials, parts, elements, features, integrals, operations, and / or process steps. In the case of “consisting of…”, the alternative embodiment excludes any additional components, materials, parts, elements, features, integrals, operations and / or process steps, while in the case of “consisting substantially of…”, any additional components, materials, parts, elements, features, integrals, operations and / or process steps that substantially affect the basic and novel characteristics are excluded from this embodiment, but any components, materials, parts, elements, features, integrals, operations and / or process steps that do not substantially affect the basic and novel characteristics may be included in the embodiment.

[0051] Unless explicitly identified as an order of execution, no method steps, procedures, and operations described herein should be construed as requiring them to be performed in the specific order discussed or shown. It should also be understood that, unless otherwise stated, additional or alternative steps may be employed.

[0052] When a component, element, or layer is referred to as being “on,” “joined to,” “connected to,” or “attached to” another component or layer, it may be directly on, directly joined to, directly connected to, or directly attached to the other component, element, or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as being “directly on,” “directly joined to,” “directly connected to,” or “directly attached to” another component or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0053] Although the terms first, second, third, etc., may be used herein to describe various steps, elements, components, regions, layers, and / or portions, these steps, elements, components, regions, layers, and / or portions should not be limited by these terms unless otherwise indicated. These terms are used only to distinguish one step, element, component, region, layer, or portion from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms, when used herein, do not imply order or sequence. Therefore, without departing from the teachings of the exemplary embodiments, the first step, element, component, region, layer, or portion discussed below may be referred to as the second step, element, component, region, layer, or portion.

[0054] For ease of description, spatial or temporal relative terms (e.g., "before," "after," "inside," "outside," "below," "under," "lower," "above," "upper," etc.) may be used herein to describe the relationship of an element or feature to another element or feature shown in the figure. Spatial or temporal relative terms may be intended to include different orientations of the device or system in use or operation other than those shown in the figure.

[0055] Throughout this disclosure, numerical values ​​represent approximate measurements or limitations of range to cover minute deviations from a given value, as well as embodiments having approximately the mentioned value and embodiments having precisely the mentioned value. Except for the working examples provided at the end of the detailed description, all numerical values ​​of parameters (e.g., quantities or conditions) in this specification (including the appended claims) should in all cases be understood to be modified by the term “about,” regardless of whether “about” actually appears before the numerical value. “About” indicates that the numerical value allows for some slight inaccuracy (some exact closeness to the numerical value; approximately or reasonably close to the value; almost). If the inaccuracy provided by “about” cannot be understood in this ordinary sense in the art, then “about” as used herein at least indicates a variation that may be caused by common methods of measuring and using these parameters. For example, “about” can include a variation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in some aspects, optionally less than or equal to 0.1%.

[0056] Furthermore, the disclosure of the range includes disclosing all values ​​within the entire range and further subdivisions of the range, including endpoints and subranges given for the range.

[0057] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0058] Structural components can be used in vehicles to provide structural support and / or mounting locations for other vehicle parts. Structural components may include energy-absorbing parts that absorb collision energy through controlled deformation. Structural components may be constructed from metals such as aluminum or steel and / or polymer composites. Metal structural components can absorb energy while undergoing elastic and / or plastic deformation without fracturing. Lower-strength metals can be assembled to additional reinforcing members to achieve the desired strength. Some structural components utilize lateral member components to achieve the desired energy absorption performance, for example, in side-impact collisions.

[0059] Some structural components are used to support and / or house one or more electrochemical devices. Such structural components may include base plate components, cover components, multiple reinforcing components, and multiple transverse member components, all of which are manufactured individually (e.g., by stamping, roll forming, or extrusion) and connected to each other (e.g., by welding). Electrochemical devices (e.g., battery modules or capacitors) may be secured to the welded transverse members (e.g., by bolting) and are at least partially protected from impact and / or contamination by the structural components.

[0060] Some structural components can be complex to assemble due to the large number of parts. Manufacturing and assembling structural components can be difficult to understand, complex, and / or time-consuming due to the number of different parts. Furthermore, metal structural components can be heavy, leading to reduced fuel efficiency and / or battery range in the vehicle.

[0061] In some encapsulated electrochemical device structural components, the maintenance, replacement, or repair of the electrochemical device can be a labor-intensive process. Cover components may be removably attached to the structural component (e.g., via mechanical fasteners). The electrochemical device may be secured to a transverse member, which may be attached (e.g., welded) to the base plate component and frame and / or side components. When the battery module is secured to the base plate, frame, and / or side components, maintenance of a single electrochemical device may involve removing the entire structural component from the vehicle. Due to the weight and number of components in the entire structural component, the maintenance process can be complex and time-consuming.

[0062] In various aspects, this disclosure provides a panel structure assembly for a vehicle. The structure assembly may include high-strength metal components, such as high-strength steel. The structure assembly includes a plurality of high-strength panels coupled to a frame. The structure assembly includes a first pair of panels, wherein the first panel is secured to a second panel (e.g., by welding). The structure assembly may also include a second pair of panels, wherein a third panel is secured to a fourth panel (e.g., by welding). Each pair of panels may be removably coupled to the frame (e.g., by clamps and / or mechanical fasteners).

[0063] In various aspects, this disclosure provides a panel structure assembly for a vehicle that has no frame. The structure assembly may include high-strength metal components (e.g., high-strength steel). The structure assembly includes a first pair of panels, wherein the first panel is fixed to the second panel (e.g., by welding).

[0064] Each panel includes a recess and a complementary protrusion. The contours of the recess and protrusion can be symmetrical. In the aggregate, the recess and complementary protrusion define a pattern on the panel. The pattern can provide the panel with increased strength in at least one direction compared to an unpatterned panel. The pattern can form at least two planes of symmetry, which provides the panel with increased strength in at least two directions compared to an unpatterned panel. The patterns of each panel in the assembly can be the same or different and can be designed to meet the desired strength and energy absorption characteristics of the structural assembly. The panel structural assembly can be configured to support other vehicle components, such as electrochemical devices. In one example, the panel structural assembly may include a cover component, a base component, and a frame, the cover component including a first pair of panels and the base component including a second pair of panels.

[0065] Panel structure assemblies made of high-strength metals can generally be simpler than other structural assemblies with more components and stiffeners. The patterned panels of a panel structure assembly can exhibit desired strength and energy absorption characteristics without the need for transverse members. Due to the increased strength of the high-strength metal, panel structure assemblies can include fewer stiffeners, transverse members, and / or fasteners. The reduction in the number of components compared to typical structural assemblies can also result in a less complex and / or more time-consuming assembly process. Furthermore, panel structure assemblies can be lightweight compared to structural assemblies that include stiffeners, transverse members, and / or fasteners.

[0066] Removably attached panels surrounding vehicle components, such as electrochemical devices, improve component maintainability. The component can be attached (e.g., via mechanical fasteners) to either a cover component or a base plate component, allowing the other of the removably attached base plate component or cover component to be removed separately from the structural assembly. In some aspects, the component can be attached to a cover component (e.g., via mechanical fasteners), allowing the base plate component to be removed separately from the structural assembly. Removing a mechanically fastened base plate or cover component allows for easier and / or faster access to the component for maintenance compared to removing the entire structural assembly from the vehicle without a removably attached panel.

[0067] Reference Figures 1A-1D A panel structure sub-assembly 10 (also referred to as "sub-assembly 10") is provided according to various aspects of this disclosure. Sub-assembly 10 includes a frame 12 and a plurality of panels 13. As will be shown in the figure... Figures 1A-1K As described in more detail, multiple panels 13 can be connected to frame 12.

[0068] Reference Figure 1E The frame 12 may include a pair of longitudinally extending sides 14 and a pair of laterally extending sides 16 (collectively referred to as "sides 14, 16"). In some respects, each of the four sides 14, 16 may be fixed substantially perpendicularly to the adjacent side, such that the longitudinally extending side 14 is fixed substantially perpendicularly to the laterally extending side 16 at a corner 18. Therefore, the frame 12 may include four corners 18, wherein each corner 18 includes a joint between one of the longitudinally extending sides 14 and one of the laterally extending sides 16. When the subassembly ( Figure 1A When the longitudinally extending side 14 (as shown in the diagram) is assembled into a vehicle, it can extend in the front-rear direction, and the laterally extending side 16 can extend in the transverse vehicle direction.

[0069] Frame 12 may include or be made of metal. In some aspects, the metal may include steel, aluminum (e.g., aluminum or aluminum alloys), or a combination of steel and aluminum. In some aspects, frame 12 may include a polymer composite material, used in combination with or alone with the metal.

[0070] Reference Figures 1E-1F In some respects, sides 14, 16 may cooperate to define a generally rectangular shape. Sides 14, 16 may include one or more hollow portions 20. Each hollow portion 20 may extend in whole or in part along the length of the respective side 14, 16. Figure 1F As shown, each side 14, 16 may be partially hollow. In some respects, each of sides 14, 16 may be substantially hollow (see example...). Figures 2C-2D ).

[0071] Sides 14 and 16 can be formed using roll forming, extrusion, or a combination of roll forming and extrusion. In some other respects, sides 14 and 16 can be formed using other methods.

[0072] Each of the sides 14 and 16 may define a height 32 (e.g., maximum height) and a width 34 (e.g., maximum width). In some respects, the height 32 is greater than or equal to about 80 mm, optionally greater than or equal to about 90 mm, optionally greater than or equal to about 100 mm, optionally greater than or equal to about 110 mm, optionally greater than or equal to about 120 mm, optionally greater than or equal to about 130 mm, optionally greater than or equal to about 140 mm, optionally greater than or equal to about 150 mm, optionally greater than or equal to about 160 mm, optionally greater than or equal to about 170 mm, optionally greater than or equal to about 180 mm, or optionally greater than or equal to 190 mm. In some respects, the height 32 is less than or equal to about 200 mm, optionally less than or equal to about 190 mm, optionally less than or equal to about 180 mm, optionally less than or equal to about 170 mm, optionally less than or equal to 160 mm, optionally less than or equal to 150 mm, optionally less than or equal to 140 mm, optionally less than or equal to about 130 mm, optionally less than or equal to about 120 mm, optionally less than or equal to about 110 mm, optionally less than or equal to about 100 mm, or optionally less than or equal to about 90 mm.

[0073] In some aspects, the width 34 is greater than or equal to about 80 mm, optionally greater than or equal to about 90 mm, optionally greater than or equal to about 100 mm, optionally greater than or equal to about 110 mm, optionally greater than or equal to about 120 mm, optionally greater than or equal to about 130 mm, or optionally greater than or equal to about 140 mm. In some aspects, the width 34 is less than or equal to about 150 mm, optionally less than or equal to about 140 mm, optionally less than or equal to about 130 mm, optionally less than or equal to about 120 mm, optionally less than or equal to about 110 mm, optionally less than or equal to about 100 mm, or optionally less than or equal to about 90 mm. The frame 12 may at least partially define the inner region 36 and the outer region 38.

[0074] In some aspects, each side 14, 16 may include a plurality of walls 40. At least a portion of the walls 40 may at least partially define the hollow portion 20. In some aspects, each side 14, 16 may include an inner portion 41, a central portion 42, and an outer portion 46. The inner portion 41 may be disposed closer to the inner region 36 of the frame 12 than the central portion 42 and the outer portion 46. The outer portion 46 may be disposed closer to the outer region 38 of the frame 12 than the central portion 42 and the inner portion 41. The central portion 42 may be disposed between the inner portion 41 and the outer portion 46. The central portion 42 may be at least partially disposed between the inner portion 41 and the outer portion 46 of the frame 12.

[0075] In some respects, the hollow portion 20 may define a generally rectangular cross-sectional shape, a generally elliptical cross-sectional shape, or a combination of cross-sectional shapes. In some respects, the wall 40 is integrally formed such that at least some of the hollow portions 20 can share walls with other portions of the hollow portion 20 (see, for example...). Figure 1F and Figure 2C However, in some other respects, the plurality of walls 40 may be joined together to at least partially define the hollow portion 20 (see, for example...). Figure 2D Sides 14 and 16 may be constructed and / or formed as needed to include different geometries, features, orientations, and / or material thicknesses of walls 40 and / or hollow portions 20 to provide structural support and / or strength in desired areas of the vehicle.

[0076] like Figure 1E As shown, in some aspects, frame 12 may include transverse members 50. Transverse members 50 may be at least partially disposed within the interior region 36 of frame 12. Transverse members 50 may further divide frame 12 into a first interior segment or portion 52 and a second interior segment or portion 54. In some aspects, the frame may include multiple transverse members dividing the interior region into more than two portions. In some other aspects, the frame may have no transverse members (e.g., see [reference needed]). Figure 2A Frame 400 and Figure 8A Framework 802).

[0077] In some aspects, the transverse member 50 may at least partially define one or more footwell areas 56. In some aspects, the transverse member 50 may include two transverse extension bars 58 and two longitudinal extension bars 60. The transverse extension bars 58 may be fixed substantially vertically to the longitudinally extending side 14 of the frame 12. The longitudinal extension bars 60 may be at least partially disposed between the two transverse extension bars 58 and fixed vertically to each transverse extension bar.

[0078] Back Figures 1A-1B Sub-component 10 includes a plurality of panels 13. The plurality of panels 13 may include a first portion or cover 72 and a second portion or base 74. The first portion 72 may include a first panel 76, and the second portion 74 may include a second panel 78. In some other aspects, each of the first and second portions 72, 74 of the plurality of panels may include more than one panel, such as a pair of panels, as shown and described in more detail below. In some other aspects, the plurality of panels 13 may include two or more panels, optionally three or more panels, optionally four or more panels, optionally five or more panels, optionally ten or more panels, or optionally fifteen or more panels.

[0079] Panel 13 may include or be made of a high-strength metal. The high-strength metal may include steel, aluminum (e.g., aluminum, aluminum alloys, such as alloys from the 6XXX and / or 7XXX series, including Al 6061, Al 6082, Al 6034, Al 6282, Al 7075, or combinations of aluminum alloys), or a combination of steel and aluminum. In some aspects, panel 13 may include a polymer composite material, either in combination with or alone from the metal. Panels made of high-strength steel may have a tensile strength greater than or equal to about 900 MPa, optionally greater than or equal to about 1,000 MPa, optionally greater than or equal to about 1,200 MPa, or optionally greater than or equal to about 1,500 MPa. Panels made of aluminum may have a yield strength greater than or equal to about 200 MPa, optionally greater than or equal to about 300 MPa, optionally greater than or equal to about 400 MPa, or optionally greater than or equal to about 500 MPa. In some aspects, the plurality of panels 13 cooperate with the sub-assembly 10 to support an external load greater than or equal to about 10 kN (e.g., when the external load is applied to the sub-assembly 10 in the longitudinal and / or vertical directions). In some aspects, the plurality of panels 13 cooperate to support an external load greater than or equal to about 50 kN, optionally greater than or equal to about 100 kN, optionally greater than or equal to about 150 kN, optionally greater than or equal to about 200 kN, optionally greater than or equal to about 250 kN, optionally greater than or equal to about 300 kN, or optionally greater than or equal to about 350 kN. In some aspects, such as when a lateral load is applied in the transverse vehicle direction, the plurality of panels cooperate to support an external load greater than or equal to about 400 kN, optionally greater than or equal to about 450 kN, or optionally greater than or equal to about 500 kN. In some aspects, each panel 13 may be configured to support an external load greater than or equal to about 100 kN.

[0080] See Figure 1G Each panel 13 may include a pair of longitudinally extending sides 90 and a pair of laterally extending sides 92 (collectively referred to as "sides 90, 92"). In some respects, as shown, at least a portion of the panel 13 may be generally rectangular in shape. Each panel 13 may include a substantially planar body 93. The sides 90, 92 may cooperate to define an outer edge or perimeter 94.

[0081] In some other respects, the panel may include additional walls, such as sidewalls, that extend substantially vertically from the substantially planar body and / or at least partially along the perimeter (see, for example, see...). Figures 3A-3EThe sidewalls may optionally vary in size and / or shape. The panel may include additional walls and / or may have different geometries (e.g., shape), features (e.g., outer edges and / or flanges) and constructions as needed to meet the desired structural and energy absorption characteristics of the sub-assembly 10.

[0082] In some respects, each panel 13 may have an average thickness greater than or equal to about 0.5 mm and less than or equal to about 5 mm. In some respects, the thickness of the entire panel 13 may be uniform; however, in some other respects, the thickness may be varied as needed to provide structural support and / or strength in desired areas of the vehicle.

[0083] Back Figure 1B The first panel 76 and the second panel 78 may respectively include or at least partially define the foot supports 110 and 112. The first panel 76 may be connected to both the third panel 120 and the fourth panel 122. In some aspects, the first panel 76 may be directly connected to the third panel 120 and the fourth panel 122. The second panel 78 may be connected to both the fifth panel 124 and the sixth panel 126. In some aspects, the second panel 78 may be directly connected to the fifth panel 124 and the sixth panel 126.

[0084] In some other respects, depending on the desired vehicle packaging and / or construction, the panel may not have a footrest structure (e.g., see...). Figures 8A-8B (Panel 804). For example, when the panel does not have a foot structure, the third and fourth panels can be integral to form a single panel that can be directly connected to the first panel, and the fifth and sixth panels can be integral to form another single panel that can be directly connected to the second panel.

[0085] Back Figure 1G Each panel 13 includes a first surface 180 and a second surface 182 opposite to the first surface 180. The first surface 180 may include or define a plurality of recesses 184. Between the recesses 184, the body 93 may include a substantially planar region 185. The second surface 182 may include or define a plurality of protrusions 186 (in... Figure 1B , 1H (As shown in the figure). Each of the recess 184 and the protrusion 186 may have a maximum depth greater than or equal to about 1 mm and less than or equal to about 10 mm. In some aspects, the recess 184 and the protrusion 186 may optionally have a maximum depth less than or equal to about 30 mm, or optionally less than or equal to 20 mm.

[0086] In some respects, the shape of the protrusion 186 is complementary to the shape of the recess 184. In some respects, the profile shapes of the recess and the complementary protrusion may be symmetrical. In some respects, as shown, the recess 184 and the complementary protrusion 186 have substantially circular profile shapes. In some respects, the recess 184 and the complementary protrusion 186 may have non-circular profile shapes (e.g., see...). Figures 3A-3E , Figures 8A-8B (The outline shape). In some other aspects, the panel may include only recesses, only protrusions, misaligned protrusions and recesses, and / or non-complementary protrusions and recesses. In some other aspects, the panel may contain neither recesses nor protrusions (e.g., having a substantially planar surface).

[0087] The aggregation of recesses 184 and complementary protrusions 186 can form a pattern 188. In some aspects, the pattern may include a randomly distributed contour shape and be substantially asymmetrical. In some aspects, the pattern may have at least one plane of symmetry. In some aspects, the pattern 188 may have at least two planes of symmetry (and optionally more than two planes of symmetry). The pattern 188 may include a first plane of symmetry 190 and a second plane of symmetry 192. The first plane of symmetry 190 and the second plane of symmetry 192 may be substantially perpendicular. The panel 13 and the pattern 188 may be formed by a method including hot stamping, cold stamping, roll forming, a combination of hot stamping, cold stamping and / or roll forming, or any other suitable method.

[0088] As shown, pattern 188 may include substantially evenly spaced circular recesses. In some other aspects, all or part of the panels in the sub-assembly may have different geometries (e.g., profile shape, size) and / or arrangements (e.g., grouped together, evenly spaced on the panels, or separated from each other) (see example...). Figures 3A-3E (and the accompanying discussion).

[0089] Due to the first and / or second symmetry planes 190, 192 of pattern 188, each panel 13 may have increased strength and / or stiffness in at least one direction compared to a panel without a pattern (e.g., a substantially flat panel consisting of substantially planar surfaces). (e.g., the panel has only the first symmetry plane 190, and has increased strength and / or stiffness parallel to the first symmetry plane 190). In some aspects, each panel may have increased strength and / or stiffness in at least one direction or optionally in at least two directions (e.g., parallel to the first symmetry plane 190 and the second symmetry plane 192) compared to a panel without a pattern. In some aspects, each panel 13 may have increased strength and / or stiffness in more than two directions (e.g., pattern 188 has more than two symmetry planes). In some aspects, each of the first portion 72 and the second portion 74 of the panel may have increased strength and / or stiffness in at least one direction compared to a portion of a panel without a pattern (e.g., a portion of a panel comprising a substantially flat panel). In some respects, each of the first portion 72 and the second portion 74 of the panel may have increased strength and / or stiffness in at least two directions compared to the unpatterned portion of the panel.

[0090] Each panel 13 may have the same pattern, such as pattern 188 as shown in the figure. In some other respects, all or some of the panels in the subassembly may differ from the other panels in the structural subassembly. In some other respects, at least a portion of the panels in the subassembly may be unpatterned. Any combination of panels, including any combination of patterns, may be utilized and arranged to provide the desired strength, stiffness, and energy absorption characteristics of the subassembly 10.

[0091] Return to reference Figure 1BThe first portion 72 of the panel includes a first panel 76, a third panel 120, and a fourth panel 122. Each panel 76, 120, 124 includes a first surface 180 having a plurality of recesses 184 and a second surface 182 having a plurality of protrusions 186. The third panel 120 and the fourth panel 122 are both oriented 180 degrees relative to the first panel 76, such that the second surface 182 of the first panel 76 faces the second surfaces 182 of the third panel 120 and the fourth panel 122. Therefore, the protrusions 186 of the first panel 76 are substantially aligned with the protrusions 186 of the third panel 120 and the protrusions 186 of the fourth panel 122. The surfaces 180, 182 of the second portion of the panel 74 may be oriented substantially similarly to the first portion of the panel 72, and the second portion of the panel 74 includes a second panel 78, a fifth panel 124, and a sixth panel 126. Each panel 78, 124, 126 includes a first surface 180 having a plurality of recesses 184 and a second surface 182 having a plurality of protrusions 186. The fifth panel 124 and the sixth panel 126 are both oriented 180 degrees relative to the second panel 78, such that the second surface 182 of the second panel 78 faces the second surfaces 182 of the fifth panel 124 and the sixth panel 126. Therefore, the protrusions 186 of the second panel 78 are substantially aligned with the protrusions 186 of the fifth panel 124 and the protrusions of the sixth panel 126.

[0092] In some other respects, (not shown) both the third panel 120 and the fourth panel 122 may be oriented in the same direction relative to the first panel 76, such that the second surface 182 of the first panel 76 faces the first surface 180 of the third panel 120 and the first surface 180 of the fourth panel 122. Therefore, the protrusion 186 of the first panel 76 is substantially aligned with the recess 184 of the third panel 120 and the recess 184 of the fourth panel 122. The surfaces 180, 182 of the second portion of the panel 74 may be oriented substantially similarly to the first portion of the panel 72.

[0093] Reference Figure 1H It provides a first panel 76, a third panel 120, and a fourth panel 122. Figure 1B The panel subassembly 194 (shown in the diagram) is shown. The second surface 182 of the first panel 76 is attachable to the second surface 182 of the third panel 120 and the second surface 182 of the fourth panel 122. In some aspects, a portion of the second surface 182 of the first panel 76 is directly attachable to a portion of the second surface 182 of the third panel 120 and the second surface 182 of the fourth panel 122. In some aspects, the first panel 76 is attached to the third panel 120 (and the fourth panel 122) by welding, adhesive, or a combination of welding and adhesive. Figure 1B(As shown in the diagram). In some respects, the second surface 182 may be joined at the first interface 196 adjacent to the periphery of the protrusion 186 and / or at the second interface 198 adjacent to the edge 94, the first panel 76 and the third panel 120 (and the fourth panel 122, in...) Figure 1B The planar region 185 (shown in the diagram) can cooperate to define multiple cavities 200. In other respects, the first panel can be coupled to another panel. For example, the first panel can be positioned between a pair of panels to define cavities on either side of the first panel. The second panel 78 can be coupled to the fifth panel 122 and the sixth panel 124 in a similar manner to those described above.

[0094] Back Figure 1C Sub-component 10 includes multiple panels 13 and frames 12 (which may be as shown in the attached figure). Figure 1I-1J , Figure 8A As described in the discussion, multiple panels 13 (including first portions 72 and second portions 74) may be at least partially disposed within the interior region 36 of the frame 12. In some aspects, the frame 72 may be oriented substantially horizontally to include a top side 202 and a bottom side 204. The first portions 72 of the panels may be attached to the top side of the frame 202, and the second portions 74 of the panels may be attached to the bottom side 204 of the frame 12. In some other aspects, the frame may be oriented substantially vertically to include a right side and a left side, wherein a first plurality of panels are fixed to the right side of the frame, and a second plurality of panels are fixed to the left side of the frame. The multiple panels may have alternative orientations and may be optimized in terms of position, geometry, and / or material to meet the desired structural, packaging, and loading characteristics of the sub-assembly 10.

[0095] refer to Figure 1I Structural component 210 is provided according to various aspects of this disclosure. Structural component 210 includes... Figures 1A-1H Sub-component 10. A first portion of panel 72 may be attached to frame 12 by one or more fasteners 212. Fasteners 212 may include mechanical fasteners. In some respects, mechanical fasteners include rivet nuts, screws, bolts, anchors, or any combination thereof. A second portion 74 of panel may be secured to frame 12 by other means (e.g., by adhesive and / or welding), or by using one or more mechanical fasteners in a manner similar to that described above with respect to the first portion 72 of panel.

[0096] refer to Figure 1J Another structural component 218 is provided according to various aspects of this disclosure. Structural component 218 includes... Figure 1A-1HSub-component 10. In some respects, frame 12 may mate with plate 220 and fastener 221 to secure the first portion 72 of the panel to frame 12 at frame sides 14, 16. The second portion 74 of the panel may be secured to frame 12 by other means (e.g., by adhesive and / or welding) or clamped in a manner similar to that described below with respect to the first portion 72 of the panel.

[0097] In some respects, plate 220 may be referred to as a “clamp” alone or in combination with frame 12 and / or fasteners. In some respects, frame 12 may cooperate with more than one fastener 221 to secure the first portion 72 of the panel, for example, two or more fasteners, optionally three or more fasteners, optionally four or more fasteners, optionally five or more fasteners, optionally six or more fasteners, optionally seven or more fasteners, optionally eight or more fasteners, optionally nine or more fasteners, or optionally ten or more fasteners.

[0098] In some respects, plate 220 may be made of steel, aluminum (e.g., aluminum, aluminum alloys, such as alloys from the 6XXX and / or 7XXX series, including Al 6061, Al 6082, Al 6034, Al 6282, Al 7075, or combinations of aluminum alloys), or a combination of steel and aluminum. Plate 220 may have an average thickness 222 of about 2 mm or more to about 10 mm or less.

[0099] The first portion 72 of the panel may be at least partially disposed between the plate 220 and the frame 12. More specifically, the first portion 72 of the panel may be sandwiched between the first portion 226 of the plate 220 and the first portion 228 of the frame 12. In some aspects, the first portion 226 of the plate 220 directly contacts the first portion 72 of the panel and has an average contact length greater than or equal to about 25 mm and less than or equal to about 50 mm from the outer edge 94 of the first portion 72 of the panel. In some aspects, the first panel 76 may directly contact the first portion 226 of the plate 220, and the third panel 120 may directly contact the first portion 228 of the frame 12. In some aspects, the second portion 230 of the plate 220 may directly contact the second portion 232 of the frame 12.

[0100] Plate 220 can apply substantially uniform pressure or clamping force to panel 13, for example, in the region adjacent to the outer edge 94 of the panel. The clamping force of plate 220 is sufficient to compress and / or eliminate vibration of panel 13 during vehicle operation. Compared with other types of fasteners, the relatively large surface area of ​​plate 220 can at least partially reduce and / or minimize stress concentration.

[0101] Reference Figure 8AThis illustrates another panel structure sub-assembly 800 (also referred to as "sub-assembly 800") according to various aspects of this disclosure. Sub-assembly 800 may be similar to Figures 1A-1K Subcomponent 10, in addition to being described in more detail below.

[0102] Sub-component 800 includes a frame 802 and a plurality of panels 804 attached to the frame 802. Except as otherwise described below, the frame 802 may be connected to... Figure 2A The frame 802 is the same as or similar to the frame 400. The frame 802 may include a pair of longitudinally extending sides 806 and a pair of laterally extending sides 808 (collectively referred to as "sides 806, 808"). The sides 806, 808 may at least partially define the interior region 830. In some respects, the frame 802 may be without additional supports, such as lateral members.

[0103] Multiple panels 804 may include a first portion or cover 810 and a second portion or base plate 812. Except as otherwise described below, the multiple panels 804 (also referred to as “panel 804”) may be coupled with… Figures 1A-1D and Figure 1G-Figure 1K The panels 13 are the same as or similar to those in the first part 810. The first part 810 may include a first panel 832 and a second panel 834. The second part 812 may include a third panel 836 and a fourth panel 838.

[0104] In some respects, sub-component 800 may include a first board 820 and a second board 822 (collectively referred to as "boards 820, 822"). Boards 820, 822 may be coupled with... Figure 1J The plates 220 are identical or similar. Each of the plates 820, 822 may include an elongated body 823 extending between a first end 824 and a second end 826. In some respects, the plates 820, 822 may have a length 828 that is substantially the same as the length of the sides 806, 808, as shown. In some respects, plates 820, 822 may have a length 828, which is a portion of the length of the frame sides 806, 808, for example, a length greater than or equal to about 50% of the length of sides 806, 808, a length greater than or equal to about 60% of the length of sides 806, 808, a length greater than or equal to about 70% of the length of sides 806, 808, a length greater than or equal to about 75% of the length of sides 806, 808, a length greater than or equal to about 80% of the length of sides 806, 808, a length greater than or equal to about 85% of the length of sides 806, 808, a length greater than or equal to about 90% of the length of sides 806, 808, or a length greater than or equal to about 95% of the length of sides 806, 808.

[0105] In some respects, subassembly 800 may include only one of these boards (e.g., first board 820 or second board 822). In some respects, as shown, subassembly 800 includes two boards. Figure 8A As best shown, the second plate 822 may be positioned on the side opposite to the first plate 820. In some aspects, plates 820 and 822 may cooperate with a longitudinally extending side 806. In some other aspects, plates 822 and 820 may be positioned to cooperate with a laterally extending side 808. In some other aspects, plates 822 and 820 may be positioned to cooperate with an adjacent side. In some aspects, subassembly 800 may include more than two plates, optionally more than or equal to three plates, or optionally more than or equal to four plates. In some aspects, each of the sides 806 and 808 may cooperate with one or more plates.

[0106] Components and sub-components according to various aspects of this disclosure can be used to support and / or house one or more vehicle parts. Return Figures 1A-1J In various aspects, and in some aspects, sub-component 10 may at least partially surround and / or support one or more electrochemical devices, such as a battery. In some aspects, sub-component 10 may at least partially surround and / or support one or more components, such as a battery disconnect unit (BDU), a busbar, a cooling panel, wires, or combinations thereof.

[0107] refer to Figure 1K A rechargeable energy storage system (“RESS”) assembly 300 is provided according to various aspects of this disclosure. The RESS assembly 300 includes a sub-assembly 10 and an electrochemical device 310, such as a battery module. The electrochemical device 310 is at least partially housed within and / or supported by the sub-assembly 10. In some respects, the cover 72 and the base plate 74 are substantially horizontally oriented.

[0108] Cover 72, base plate 74 and frame 12 ( Figure 1D (As shown) can cooperate to define an internal chamber 350. An electrochemical device 310 is at least partially disposed within the internal chamber 350. In some aspects, the electrochemical device 310 is entirely disposed within the internal chamber 350. In some aspects, the electrochemical device 310 may be attached to a cover 72. The electrochemical device 310 may be attached to the cover 72 by one or more mechanical fasteners 352, as shown. Alternatively or additionally, the electrochemical device 310 may be attached to the cover by one or more welds and / or adhesives.

[0109] Alternatively or concurrently, the electrochemical device 310 may be attached to the base plate 74. The electrochemical device 310 may be attached to the base plate 74 by one or more mechanical fasteners, one or more welded components, adhesives, or any combination thereof (not shown). Directly attaching the electrochemical device 310 to either the cover 72 or the base plate 74 facilitates easy removal of the other of the cover 72 and the base plate 74 from the RESS assembly 300.

[0110] According to certain aspects of this disclosure, component 210 (such as...) Figure 1I As shown), 218 (as shown) Figure 1J (as shown), 300 (as shown) Figure 1K (as shown) and 800 (as shown) Figure 8A (As shown) This facilitates easy maintenance or replacement of components, such as the electrochemical device 310. In some respects, the cover 72 and / or the base plate 74 can be removably attached to the frame 12 (e.g., mechanically secured by clamps and / or mechanical fasteners, such as...). Figure 1I-1J and Figure 8A (As shown in the diagram). RESS component 310 can be attached (e.g., bolted) to one of cover 72 or base plate 74, and the other of cover 72 and base plate 74 can be at least partially removable to provide access to components such as electrochemical device 310, as... Figure 1K As shown in the diagram. Removing the mechanically fastened cover 72 or base plate 74 allows for easier access to maintain or replace parts compared to removing the entire structural assembly 300.

[0111] Structural components according to various aspects of this disclosure may include frame 12, such as Figure 1A-1F The frame shown in 1I-1K, or another frame that differs from frame 12 in the presence or number of support members (e.g., transverse members), manufacturing method, construction material, shape and / or size. Figures 2A-2D Other frameworks are described based on certain aspects of this disclosure.

[0112] refer to Figure 2A This provides another framework 400 according to various aspects of this disclosure. Framework 400 can be used with... Figures 1A-1F and Figure 1I-Figure 1K The frame 12 is the same as or similar to the frame 12, except as otherwise described below. The frame 400 may include a pair of longitudinally extending sides 404 and a pair of laterally extending sides 406 (collectively referred to as "sides 404, 406"). Sides 404, 406 may at least partially define the interior region 410. In some aspects, the frame 400 may be without additional supports, such as transverse members. The interior region 410 may be uninterrupted and continuous. In some aspects, the frame 12 is substantially composed of sides 404, 406.

[0113] See Figure 2B This provides another framework 412 according to various aspects of this disclosure. Framework 412 can be combined with... Figures 1A-1F and 1I- Figure 1K The frame 412 is the same as or similar to the frame 12, except as otherwise described below. The frame 412 includes a pair of longitudinally extending sides 414 and a pair of laterally extending sides 416 (collectively referred to as "sides 414, 416"). The sides 414, 416 may at least partially define the interior region 420. In some aspects, the frame 412 may include a single lateral member 424.

[0114] A transverse member 424 may be arranged at least partially in the interior region 420. The transverse member 424 may divide the interior region into a first interior segment or portion 426 and a second interior segment or portion 428. The transverse member 424 is fixed to or integrally formed with the longitudinally extending side 414 and may extend substantially parallel to the transversely extending side 416. In other respects, the transverse member may be fixed to or integrally formed with the transversely extending side and extend substantially parallel to the longitudinally extending side. Although the first interior portion 426 and the second interior portion 428 are substantially equal in size and shape, the frame may have other constructions (e.g., different relative dimensions of the interior segments) and / or additional supports, such as the transverse member.

[0115] Reference Figure 2C A partial section of another frame 440 is provided according to various aspects of this disclosure. Frame 440 can be connected with... Figures 1A-1F and Figure 1I-Figure 1K The frame 440 is the same as or similar to the frame 12, except as otherwise described below. The frame 440 includes a plurality of sides 441 (e.g., longitudinally extending sides and laterally extending sides). The frame 440 may at least partially define an inner region 442 and an outer region 443.

[0116] Each side 441 may include a plurality of walls 444. The walls 444 may cooperate to at least partially define a plurality of elongated hollow regions 446. In some aspects, the cross-sectional shape of the elongated hollow regions 446 may be generally rectangular, trapezoidal, triangular, elliptical, or any combination thereof. In some aspects, at least a portion of the elongated hollow regions 446 may share a wall 444.

[0117] See Figure 2D Provided is a partial cross-section of another frame 460 according to various aspects of this disclosure. Frame 460 can be connected with... Figure 2C The frame 440 is the same as or similar to the frame 460, except as otherwise described below. The frame 460 includes sides 461 (e.g., longitudinally extending sides and laterally extending sides). The frame 460 may at least partially define an inner region 462 and an outer region 463.

[0118] Side 461 may include a plurality of walls 464. The plurality of walls may cooperate to at least partially define a plurality of elongated hollow regions 466. In some aspects, at least a portion of the walls 464 are joined together (e.g., by welding) to form side 461. In some aspects, each elongated hollow region 466 may have a different wall that is not shared with another elongated hollow region 466.

[0119] Structural components according to various aspects of this disclosure may include panel 13 (e.g., Figures 1A-1D and 1G- Figure 1K As shown), panel 804 (as shown) Figures 8A-8B (as shown in the image) or other panels that differ from panel 13 in geometry (shape of the panel, including sidewalls or centerwalls), manufacturing method, construction materials and / or protrusions and / or recesses. Figures 3A-3E Other panels are depicted in accordance with certain aspects of this disclosure.

[0120] As an example, protrusions and depressions can have any suitable shape, such as circles ( Figure 1G ),diamond( Figure 3A ),honeycomb( Figure 3B ),rectangle( Figure 3C , 3E 8A), L-shaped or other angled geometric shapes ( Figure 3D (or any combination thereof.) In some respects, the depressions and protrusions may be asymmetrical. In some respects, the depressions and protrusions may have at least one line of symmetry. In some respects, the depressions and protrusions may have at least two lines of symmetry (and optionally more than two lines of symmetry). The protrusions and depressions may have substantially uniform spacing ( Figure 1G , Figures 3A-3D , Figure 8A In some respects, protrusions and depressions can have uneven spacing to facilitate customized strength. Figure 3E The protrusions and recesses may be substantially identical in shape and size throughout the panel. In some respects, the panel may have more than one type of protrusion and / or recess in shape and / or size. Furthermore, multiple panels may comprise any combination of panels with the same or different patterns.

[0121] refer to Figure 3A A panel 470 is provided according to various aspects of this disclosure. The panel 470 may have a first surface 472 and a second surface 474 opposite to the first surface. The first surface 472 may include or define a plurality of recesses 476. The second surface 474 may include or define a plurality of protrusions (not shown). The shape of the protrusions may be complementary to the shape of the recesses 476. In some aspects, each of the recesses 476 and the protrusions may define a generally rhomboid profile.

[0122] refer to Figure 3B A panel 480 is provided according to various aspects of this disclosure. The panel 480 may have a first surface 482 and a second surface 484 opposite to the first surface. The first surface 482 may include or define a plurality of recesses 486. The second surface 484 may include or define a plurality of protrusions (not shown). The shape of the protrusions may be complementary to the shape of the recesses 486. In some aspects, each of the recesses 486 and the protrusions may define a substantially honeycomb or hexagonal profile.

[0123] refer to Figure 3C A panel 500 is provided according to various aspects of this disclosure. The panel 500 may have a first surface 502 and a second surface 504 opposite to the first surface. The first surface 502 may include or define a plurality of recesses 506. The second surface 504 may include or define a plurality of protrusions (not shown). The shape of the protrusions may be complementary to the shape of the recesses 506. In some aspects, each of the recesses 506 and protrusions may define a generally rectangular profile. In some aspects, the recesses 506 and protrusions may cooperate to define a corrugated pattern.

[0124] In some aspects, panel 500 may also include a longitudinal ridge 508 extending between the recess 506 and the protrusion and substantially perpendicular to the recess and protrusion. The longitudinal ridge 508 may project from the first surface 502 in a direction opposite to that of the recess 506. The longitudinal ridge 508 may be present to meet packaging and / or strength requirements. In some aspects, panel 500 may not have the longitudinal ridge 508, and the corrugated pattern may be substantially uninterrupted across surfaces 502, 504 (see example...). Figure 8A Panel 804).

[0125] refer to Figure 3D A panel 510 is provided according to various aspects of this disclosure. The panel 510 may have a first surface 512 and a second surface 514 opposite to the first surface. The first surface 512 may include or define a plurality of recesses 516. The second surface 514 may include or define a plurality of protrusions (not shown). The shape of the protrusions may be complementary to the shape of the recesses 516. In some aspects, each recess 516 and protrusion may define a substantially L-shaped or angular profile. The panel 510 may have increased strength in at least two directions.

[0126] In various aspects, the panel may include recesses and protrusions that are substantially evenly spaced, such as Figures 3A-3D As shown in the image.

[0127] In various other respects, the panel may include non-uniformly spaced protrusions and recesses to enhance customized strength. In other respects, the panel may have a combination of uniformly and non-uniformly spaced recesses and protrusions.

[0128] refer to Figure 3EAnother panel 520 is provided according to various aspects of this disclosure. Panel 520 includes a first surface 522 and a second surface 524 opposite to the first surface 522. The first surface 522 may include or define a plurality of recesses (not shown). The second surface 524 may include or define a plurality of protrusions 526. The protrusions 526 may be elongated or rectangular in shape and extend in a substantially transverse direction.

[0129] In some respects, the protrusions 526 may be spaced closer together in the first or central region 528 of the panel 520, and spaced further apart in the second or outer region 530 of the panel 520. The first region 528 may have a higher intensity than the second region 530. The panel may include additional regions with higher or lower intensity and / or intensity gradients.

[0130] Re-reference Figure 8A The diagram illustrates a sub-assembly 800 including a frame 802, multiple panels 804, and plates 820, 822. Each panel 804 may be generally rectangular in shape. Each panel 804 may include a generally planar body 840. Each panel 804 may include a pair of longitudinally extending sides 842 and a pair of laterally extending sides 844 (collectively referred to as "sides 842, 844"). The longitudinally extending sides 842 may include a first side 845 and a second side 846. The laterally extending sides 840 may include a third side 847 and a fourth side 848. The sides 842, 844 may cooperate to define an outer edge or perimeter 849.

[0131] Each panel 804 includes a first surface 850 and a second surface 852 opposite to the first surface 850. The first surface 850 may include or define a plurality of recesses or valleys 854. Between the recesses 854, a body 826 may include a plurality of substantially planar regions 855. The second surface 852 may include or define a plurality of protrusions or ridges 856. The shape of the protrusions 856 may be complementary to the shape of the recesses 854. In some respects, each of the recesses 854 and the protrusions 856 may define a substantially circular and / or ribbed shape. The plurality of recesses 854 and the plurality of protrusions 856 may cooperate to define a corrugated pattern 860.

[0132] A first portion of panel 810 includes a first panel 832 and a second panel 834. Each of panels 832 and 834 includes a first surface 850 having a plurality of recesses 854 and a second surface 852 having a plurality of protrusions 856. The second panel 834 may be oriented 180 degrees relative to the first panel 832 such that the second surface 852 of the first panel 832 faces the second surface 852 of the second panel 834. Thus, the protrusions 856 of the first panel 832 are substantially aligned with the protrusions 856 of the second panel 834. The surfaces 850 and 852 of a second portion of panel 812 may be oriented substantially similarly to the first portion of panel 810. The second portion of panel 812 includes a third panel 836 and a fourth panel 838. Each of panels 836 and 838 includes a first surface 850 having a plurality of recesses 854 and a second surface 852 having a plurality of protrusions 856. The fourth panel 838 can be oriented 180 degrees relative to the third panel 836, such that the second surface 852 of the third panel 836 faces the second surface 852 of the fourth panel 838. Therefore, the protrusion 856 of the third panel 836 is substantially aligned with the protrusion 856 of the fourth panel 838.

[0133] In some respects, panel 804 may include substantially uniformly spaced recesses 854 and protrusions 856 to facilitate customized strength and / or stiffness. For example... Figure 8B As best illustrated, each of the recesses 854 may define a depth 870 (e.g., maximum depth) and a width 872 (e.g., average width). The depth 870 may be greater than or equal to about 1 mm and less than or equal to about 10 mm. The width 872 may be greater than or equal to about 5 mm and less than or equal to about 250 mm.

[0134] Each recess 854 may include a pair of sides 874 (also referred to as "sides 874"). Sides 874 may define a length 875. In some aspects, the length 875 may be greater than or equal to about 1 mm, optionally greater than or equal to about 1.5 mm, optionally greater than or equal to about 2 mm, optionally greater than or equal to about 2.5 mm, optionally greater than or equal to about 3 mm, optionally greater than or equal to about 3.5 mm, optionally greater than or equal to about 4 mm, optionally greater than or equal to about 4.5 mm, optionally greater than or equal to about 5 mm, optionally greater than or equal to about 5.5 mm, or optionally greater than or equal to about 6 mm. Sides 874 may be oriented at an angle 876 relative to the recess 854 (e.g., relative to the maximum depth of the recess 854). Angle 876 may be greater than or equal to about 110 degrees to less than or equal to about 160 degrees.

[0135] Multiple recesses 854 may be spaced apart such that each of the substantially planar regions 855 has a width 878 (e.g., a maximum width). The width 878 may be greater than or equal to about 5 mm to less than or equal to about 250 mm.

[0136] In one example, panel 804 may be formed of steel with an average tensile strength of about 980 MPa. Panel 804 may have an average thickness greater than or equal to about 0.9 mm and less than or equal to about 1 mm. The depth 870 of recess 854 may be about 3.75 mm. The width 872 of the plurality of recesses 854 may be about 25 mm. The length 875 of side edge 874 may be about 4.5 mm. The angle 876 may be about 124 degrees. The width 878 of substantially flat area 855 may be about 25 mm.

[0137] In another example, panel 804 may be formed of steel with an average tensile strength of about 980 MPa. Panel 804 may have an average thickness of about 2 mm. The depth 870 of recess 854 may be about 3.75 mm. The width 872 of the plurality of recesses 854 may be about 50 mm. The length 875 of side edge 874 may be about 4.5 mm. Angle 876 may be about 124 degrees. The width 878 of substantially flat area 855 may be about 50 mm.

[0138] In another example, panel 804 may be formed of steel having an average tensile strength of approximately 1350 MPa. Panel 804 may have an average thickness of approximately 0.75 mm. The depth 870 of recess 854 may be approximately 3.75 mm. The width 872 of the plurality of recesses 854 may be greater than or equal to approximately 13 mm to less than or equal to approximately 15 mm. The length 875 of side edge 874 may be approximately 4.5 mm. The angle 876 may be approximately 124 degrees. The width 878 of substantially flat area 855 may be approximately 5 mm.

[0139] In another example, panel 804 may be formed of steel with an average tensile strength of about 1500 MPa. Panel 804 may have an average thickness of about 1 mm. The depth 870 of recess 854 may be about 3.75 mm. The width 872 of the plurality of recesses 854 may be about 19 mm. The length 875 of side edge 874 may be about 4.5 mm. The angle 876 may be about 124 degrees. The width 878 of substantially flat area 855 may be about 19 mm.

[0140] In another example, panel 804 may be formed of steel with an average tensile strength of about 1500 MPa. Panel 804 may have an average thickness of about 2 mm. The depth 870 of recess 854 may be about 3.75 mm. The width 872 of the plurality of recesses 854 may be about 39 mm. The length 875 of side edge 874 may be about 4.5 mm. The angle 876 may be about 134 degrees. The width 878 of substantially flat area 855 may be about 39 mm.

[0141] In another example, panel 804 may be formed of aluminum with an average tensile strength of about 270 MPa. Panel 804 may have an average thickness of about 2 mm. The depth 870 of recess 854 may be about 3.75 mm. The width 872 of the plurality of recesses 854 may be about 100 mm. The length 875 of side edge 874 may be about 4.5 mm. The angle 876 may be about 124 degrees. The width 878 of substantially flat area 855 may be about 100 mm.

[0142] In another example, panel 804 may be formed of aluminum with an average tensile strength of about 270 MPa. Panel 804 may have an average thickness of about 4 mm. The depth 870 of recess 854 may be about 3.75 mm. The width 872 of the plurality of recesses 854 may be about 200 mm. The length 875 of side edge 874 may be about 4.5 mm. The angle 876 may be about 124 degrees. The width 878 of substantially flat area 855 may be about 200 mm.

[0143] In another example, panel 804 may be formed of aluminum with an average tensile strength of approximately 480 MPa. Panel 804 may have an average thickness of approximately 2 mm. The depth 870 of recess 854 may be approximately 3.75 mm. The width 872 of the plurality of recesses 854 may be approximately 62 mm. The length 875 of side edge 874 may be approximately 4.5 mm. The angle 876 may be approximately 124 degrees. The width 878 of the substantially flat area 855 may be approximately 62 mm.

[0144] In another example, panel 804 may be formed of aluminum with an average tensile strength of approximately 520 MPa. Panel 804 may have an average thickness of approximately 4 mm. The depth 870 of recess 854 may be approximately 3.75 mm. The width 872 of the plurality of recesses 854 may be approximately 130 mm. The length 875 of side edge 874 may be approximately 4.5 mm. The angle 876 may be approximately 124 degrees. The width 878 of the substantially flat area 855 may be approximately 130 mm.

[0145] Return to view Figure 8AIn some aspects, the corrugated pattern 860 may extend uninterruptedly across the entire panel 804, as shown. In some aspects, the panel 804 may include a flat edge or perimeter (not shown) adjacent to the outer edge 849 (see, for example, see...). Figures 9A-9C The corrugated pattern 860 may extend uninterruptedly across the panel 804 between the body 840 and the flat edge. In some other respects, the panel 804 may have additional protrusions or features that interrupt the corrugated pattern 860 (see, for example...). Figure 3C (Vertical ridge 508). In some respects, the corrugated pattern 860 may extend only along a portion of the panel 804.

[0146] In various aspects, panel 804 can have increased strength in the direction of the corrugated pattern compared to a panel without a corrugated pattern (e.g., a substantially flat panel consisting of substantially flat surfaces). In some aspects, such as Figure 8A As shown, the corrugated pattern 860 extends along a first direction 880 between the first side 845 and the second side 846. Compared to a substantially flat panel without corrugations, panel 804 may have increased strength and / or stiffness in the first direction 880. In some other aspects, the corrugated pattern 860 may extend along a second direction (not shown) between the third side 847 and the fourth side 848. The second direction may be substantially perpendicular to the first direction 880. Compared to a substantially flat panel without corrugations, panel 804 may have increased strength and / or stiffness in the second direction. In some other aspects, the corrugated pattern 860 may extend in a third direction, such as in a diagonal direction across panel surface 850 (e.g., the third direction may be oriented at a 45-degree angle relative to the first direction 880). The wavy pattern 860 may extend in alternative directions, such as at a 15-degree angle relative to the first direction 880, optionally at a 30-degree angle relative to the first direction 880, optionally at a 45-degree angle relative to the first direction 880, optionally at a 60-degree angle relative to the first direction 880, or optionally at a 75-degree angle relative to the first direction 880.

[0147] Each panel 804 may have the same corrugated pattern, such as the corrugated pattern 860 shown in the figure. In some other aspects, all or part of the panels in the subassembly may have different corrugation directions and / or arrangements (e.g., evenly spaced on the panels, or separated from each other) as needed to achieve the strength and / or stiffness characteristics of the subassembly. In some other aspects, all or part of the panels in the subassembly may have a geometry (e.g., profile shape) different from the corrugated pattern (see, for example...). Figures 1A-1D , Figure 1G-Figure 1K , Figures 3A-3E (and the attached discussion).

[0148] Multiple panels 804 (including a first portion 810 and a second portion 812) may be at least partially disposed within an interior region 830 of a frame 802. In some respects, the frame 802 may cooperate with plates 820, 822 and a plurality of fasteners (not shown) to secure the first portion of panel 810 to the frame 802, as previously described. The second portion of panel 812 may be secured to the frame 802 in other ways (e.g., by mechanical fasteners, adhesives, and / or welds) or clamped in a manner similar to that described above with respect to the first portion 810 of the panel.

[0149] In various aspects, sub-assembly 800 can be used to house or support one or more vehicle components. In some aspects, sub-assembly 800 can at least partially surround and / or support one or more electrochemical devices. Similar to Figure 1K The RESS component 300 may include an electrochemical device that is at least partially housed within and / or supported by the sub-component 800.

[0150] In some respects, such as when subassembly 800 supports the electrochemical device, the first portion 810 of subassembly 800 can be configured as a vehicle floor (e.g., the first portion 810 is integrally formed into the vehicle's lower body structure). The electrochemical device can be fully disposed between the first portion 810 and the second portion 812 and sealed against the lower body structure. Due to the corrugated pattern 860, each panel of the second portion 812 can have increased strength and / or stiffness compared to a panel without a corrugated pattern (e.g., a substantially flat panel consisting of substantially planar surfaces). The increased strength of the panels of the second portion 812 can be sufficient to allow the second portion 812 to cooperate with external fixing devices to lift the electrochemical device into the vehicle during assembly.

[0151] In various aspects, this disclosure provides a structural assembly configured to guide and / or discharge fluid. (Refer to...) Figures 4A-4B A structural component 540 is provided according to various aspects of this disclosure. The structural component 540 includes a plurality of panels 542. The plurality of panels 542 may include a first panel 544 and a second panel 546. Figure 4B Except as otherwise described below, the first panel 544 and the second panel 546 may be coupled with Figure 1D The first panel 76 and the third panel 120 are identical or similar. The first panel 544 may cooperate with the second panel 546 to at least partially define one or more cavities 560. Figure 4B ).

[0152] In some respects, cavity 560 may be configured to discharge and / or guide fluid (e.g., air, gas). Panel 542 may include or define inlet port 570 and outlet port 572. Figure 4A Fluid 562 may enter cavity 560 at inlet port 570. Fluid 562 may be guided through cavity 560 and exit at outlet port 572.

[0153] In various aspects, this disclosure provides a structural component that includes barrier materials, such as thermal barrier materials, noise isolation materials, reinforcing materials, sealant materials, or combinations thereof.

[0154] In one example, structural components according to certain aspects of this disclosure at least partially surround the electrochemical device (e.g., see [reference]). Figure 1K Structural components include thermal barrier materials. Electrochemical devices can generate heat during operation. Thermal barrier materials can help reduce heat transfer between electrochemical devices, structural components, and other vehicle parts.

[0155] In another example, a structural component according to certain aspects of this disclosure may support a door or other body panel component. The structural component may include noise-isolating material. Noise-isolating material can help reduce noise, such as vibrations or clicking sounds from vehicle components when the vehicle is in motion.

[0156] In another example, structural components may include reinforcing materials. Reinforcing materials can increase the overall strength and / or stiffness of the structural components in areas where higher strength and / or stiffness is required.

[0157] In yet another example, the structural component may be used in an environment exposed to water, dust, or other external contaminants (e.g., when constructed as a vehicle floor panel). The structural component may include a sealant material. The sealant material can protect the component from water, dust, and / or external contaminants.

[0158] refer to Figure 5 Structural component 590 is provided according to various aspects of this disclosure. Structural component 590 includes a plurality of panels 600, which are connected to… Figures 1A-1D , Figure 1G-Figure 1K Multiple panels 13 or Figures 8A-8B The panels 804 are identical or similar. Therefore, the plurality of panels includes a first panel 612 and a second panel 614. The first and second panels 612, 614 may cooperate to define one or more cavities 620.

[0159] Barrier material 622 may be present between one or more pairs of panels (e.g., within the base plate and / or within the cover). In some aspects, barrier material 622 may be at least partially disposed within all or a portion of cavity 620. Barrier material 622 may occupy all or a portion of each cavity. Barrier material 622 may include thermal barrier material, noise isolation material, sealant material, or a combination thereof. In some aspects, thermal barrier material may include expandable foam, aerogel, or any combination thereof. In some aspects, noise isolation material may include noise, vibration, and harshness (NVH) foam (e.g., suitable NVH tape, expandable NVH tape, or EPDM foam), other suitable sound insulation material, or both NVH foam and suitable sound insulation material. In some aspects, sealant material may include polyurethane, silicone, nitrile, neoprene, ethylene propylene diene monomer (EPDM) rubber, any suitable sealant material, or a combination thereof.

[0160] In various aspects, structural components may include along Figures 9A-9D The sealant material applied to the edges or perimeter of the panel shown.

[0161] Reference Figure 9A Structural component 900 is provided according to various aspects of this disclosure. Structural component 900 includes components related to... Figures 8A-8B Multiple panels 804 are identical or similar to multiple panels 902. Therefore, the structural assembly 900 includes a first portion of the panels 904 connected to the frame 906 via plates 908 (and one or more fasteners, not shown). The first portion of the plates 904 may include a first panel 910 having a first edge portion 912 and a second panel 914 having a second edge portion 916 (collectively referred to as "panels 910, 914" and "edge portions 912, 916"). The edge portions 912, 916 may be substantially planar.

[0162] In some respects, subcomponent 900 may include... Figure 5 The sealant material 918 is the same as or similar to the sealant material, except as described below. The sealant material 918 intersects with one or more of the edge portions 912, 916 (e.g., it may directly contact one or more of the edge portions 912, 916). The interface region 920 may have an average contact area greater than or equal to about 10 mm and less than or equal to about 25 mm. In some aspects, the interface region 920 may span the entire length of a panel side. In some aspects, the interface region 920 may span the entire length of a pair of side edges (e.g., along...). Figure 8A The length of the longitudinally extending side 806). In some respects, the interface area 920 may span the entire edge or perimeter of the panel (e.g., along the length of the longitudinally extending side 806). Figure 8A (edge ​​849). In some other respects, the interface region 920 may extend only a portion of the length or a portion of one or more sides.

[0163] In some respects, such as Figure 9A As shown, edge portions 912 and 916 are formed to extend substantially parallel to the planar surface 921 of panels 910 and 914, such that the first edge portion 912 and the second edge portion 916 are spaced apart and parallel. In some respects, the first edge portion 912 is in direct contact with the plate 908.

[0164] Metal material 922 may be at least partially disposed between and in direct contact with the first edge portion 912 and the second edge portion 916. Metal material 922 may be configured to maintain a parallel spacing between the edge portions 912, 916 (e.g., when pressure is applied via plate 908 to secure panels 910, 914 to frame 906). In some aspects, metal material 922 may support panels 910, 914 to prevent buckling under applied external loads. In some aspects, metal material 902 may be made of steel, aluminum (e.g., aluminum, aluminum alloys, such as alloys from the 6XXX and / or 7XXX series, including Al 6061, Al 6082, Al 6034, Al 6282, Al 7075, or combinations of aluminum alloys), or a combination of steel and aluminum. In some aspects, metal material 920 may be the same material as panels 910, 914 (e.g., a metal material made of steel may be used in combination with panels made of steel). The sealant material 918 may be at least partially disposed between and in direct contact with the second edge portion 916 and the frame 906. In some respects, the frame 906, plate 908, panels 910, 914, and sealant material 918 cooperate to form a seal. The seal may be formed between the second panel 914 and the frame 906.

[0165] Reference Figure 9B Another structural component 950 is provided according to various aspects of this disclosure. Structural component 950 is compatible with... Figure 9AThe structural component 900 is the same as or similar to the frame 954 except as described below. The structural component 900 includes a first portion of a panel 952 connected to the frame 954 via a plate 956. The first portion of the panel 952 may include a first panel 958 having a first edge portion 960 and a second panel 962 having a second edge portion 964 (collectively referred to as "panels 958, 962" and "edge portions 960, 964"). Each of the edge portions 960, 964 may be formed to include a curved portion 966 and a flat portion 968. The panels 958, 962 may be oriented such that the flat portion 968 of the first edge portion 960 is in direct contact with the flat portion 968 of the second edge portion 964. A first sealant material 970 may be at least partially disposed between the first edge portion 960 and the plate 956, such that a first portion 972 of the first sealant material 970 is in direct contact with the plate 956, and a second portion 974 of the first sealant material 970 is in direct contact with the first edge portion 960. The second sealant material 976 may be disposed at least partially between the second edge portion 964 and the frame 954, such that the first portion 978 of the second sealant material 976 is in direct contact with the second edge portion 964 and the second portion 980 of the second sealant material 976 is in direct contact with the frame 954.

[0166] In some respects, frame 954, plate 956, panels 958, 962, first sealant material 970, and second sealant material 976 cooperate to form a seal. The seal can be formed between plate 956 and the first panel 958, and between the second panel 962 and frame 954.

[0167] In some respects, the first sealant material 970 may be the same as the second sealant material 976. In some other respects, the first sealant material 970 may be different from the second sealant material 976.

[0168] Reference Figure 9C Another structural component 1000 is provided according to various aspects of this disclosure. Structural component 1000 is compatible with... Figure 9AThe structural components 900 are the same as or similar to those described below. Structural component 1000 includes a first portion of a panel 1002 connected to frame 1004 via plate 1006. The first portion of panel 1002 may include a first panel 1008 having a first edge portion 1010 and a second panel 1012 having a second edge portion 1014 (collectively referred to as "panels 1008, 1012" and "edge portions 1010, 1014"). In some aspects, the first edge portion 1010 is formed to extend substantially parallel to the planar surface 1016 of the first panel 1008. In some aspects, the second edge portion 1014 may include a curved portion 1018 and a flat portion 1020. The curved portion 1018 may cooperate to directly connect the flat portion 1020 of the second edge portion 1014 to the first edge portion 1010.

[0169] In some aspects, the first edge portion 1010 may be at least partially disposed between the plate 1006 and the flat portion 1020 of the second edge portion 1014 and in direct contact with the plate 1006 and the flat portion 1020 of the second edge portion 1014. In some aspects, the sealant material 1022 may be at least partially disposed between the flat portion 1020 of the second edge portion 1014 and the frame 1004, such that the sealant material 1022 is in direct contact with the second edge portion 1014 and the frame 1004.

[0170] In some respects, the frame 1004, plate 1006, panels 1008, 1012, and sealant material 1022 cooperate to form a seal. The seal may be formed between the second panel 1012 and the frame 1004.

[0171] Reference Figure 9D Structural component 1050 is provided according to various aspects of this disclosure. Structural component 1050 is compatible with... Figure 9A Structural component 900 or Figure 9CThe structural component 1000 is the same as or similar to the structural component 1050, except as described below. The structural component 1050 includes a first portion of a panel 1052 connected to a frame 1054 via a plate 1056. The first portion of the plate 1052 may include a first panel 1058 and a second panel 1060 (collectively referred to as "panels 1058, 1060"). Panels 1058, 1060 may include or define an edge portion 1062. A sealant material 1064 may be at least partially disposed in the edge portion 1062. The sealant material 1064 may be at least partially disposed between a first surface 1066 of the second panel 1060 and the frame 1054. The first surface 1066 may include or define a plurality of recesses 1068. In some respects, the sealant material 1064 may be in direct contact with the plurality of recesses 1068 and the frame 1054 (e.g., filling or sealing the recesses 1068 at least partially disposed in the edge portion 1062). In some respects, a seal is formed between the second panel 1060 and the frame 1054.

[0172] As described above, structural components according to various aspects of this disclosure can be configured to provide easy and / or convenient access to an interior region that may enclose and / or support vehicle components. In some examples, the vehicle components include electrochemical devices. Electrochemical devices may include batteries (e.g., pouch cells or can cells). In some aspects, the structural component may surround and / or support components such as battery disconnect units (BDUs), busbars, cooling panels, wiring, or combinations thereof. In some aspects, the electrochemical device may substantially fill the interior region of the structural component. In other aspects, the electrochemical device may be present only in a portion of the interior region.

[0173] refer to Figure 6A A RESS assembly 650 is provided according to various aspects of this disclosure. The RESS assembly 650 may include a plurality of pouch-type battery cells 652. The RESS assembly 650 may further include a plurality of battery module housings (not shown) coupled to the pouch-type battery cells 652. The pouch-type battery cells 652 may substantially fill the internal region 654 of the RESS assembly 650. In other variations, the structural components may include modules and / or pouch-type battery cells of another size (e.g., double-wide module housings, or cell-to-pack (CTP, module-free) constructions of pouch-type battery cells) or combinations of module and / or pouch-type battery cell sizes.

[0174] refer to Figure 6BThe present disclosure provides an RESS assembly 660 according to various aspects thereof. The RESS assembly 660 may include a plurality of battery canister cells 662. The battery canister cells 662 may substantially fill the internal region 664 of the RESS assembly 660.

[0175] refer to Figure 6C The present disclosure provides a RESS assembly 670 according to various aspects thereof. The RESS assembly 670 includes a plurality of pouch-type battery units 672 (and optionally a module housing) and a plurality of canister-type battery units 674. In some aspects, the canister-type battery units 674 are disposed between two portions of the pouch-type battery units 672.

[0176] refer to Figure 6D A RESS assembly 680 is provided according to various aspects of this disclosure. The RESS assembly 680 includes a plurality of pouch cell units 682. Each pouch cell unit 682 may occupy only a portion of the internal region 684 of the RESS assembly 680. Therefore, the RESS assembly 680 may include an open region 686 (which is part of the internal region 684) without electrochemical devices or other vehicle components. As an example, the open region 686 may allow a single vehicle owner to modify the RESS assembly 680 in aftermarket service to include additional electrochemical devices.

[0177] In various respects, this disclosure also provides a method for manufacturing structural components. (See reference...) Figure 7 The present disclosure provides methods for manufacturing structural components according to various aspects thereof. The method typically includes: forming a panel at 710; optionally at least partially disposing a barrier material between the panels at 711; connecting at least portions of the panels to each other at 712; connecting the plurality of panels to the frame at 714; and optionally, at 716, disposing a vehicle component, such as an electrochemical device, in an interior region.

[0178] At 710, the method includes forming a panel. In some aspects, forming the panel includes techniques such as hot stamping, cold stamping, rolling, or a combination of hot stamping, cold stamping, and / or rolling. In some aspects, forming may further include creating sidewalls extending vertically along the periphery of the panel. The sidewalls may be formed by stretching, extrusion, roll forming, or any combination thereof.

[0179] At point 711, the method includes disposing a barrier material, at least partially, on all or a portion of at least one panel. In one example, the barrier material may be at least partially laminated near at least one panel.

[0180] At 712, the method includes joining at least a portion of the panels to one another to form a base plate or cover. Joining may include welding and / or adhering the panels to each other. In some aspects, joining may include directly joining a first panel to a second panel.

[0181] At 714, the method includes attaching a panel to a frame. The panel can be attached to the frame using mechanical fasteners (e.g., by bolts), clamps (e.g., plates), welds, adhesives, or any combination thereof. In some respects, as described above, certain attachment methods such as mechanical fasteners and clamps facilitate easy, quick, and / or convenient removal of one or more panels to provide access to internal areas of the structural component.

[0182] At point 716, the method may include placing the electrochemical device in an internal region of the structural assembly and coupling the electrochemical device to the structural assembly. For example, the electrochemical device may be coupled to a base plate and / or a cover. Mechanical fasteners, weldments, adhesives, or any combination thereof may be used to attach the electrochemical device to the structural assembly.

[0183] The above description of embodiments has been provided for illustrative and descriptive purposes. It is not intended to be exhaustive or limiting of this disclosure. Various elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in selected embodiments even if not specifically shown or described. Similarly, many variations are also possible. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A structural component, comprising: A frame, the frame including walls that at least partially define an interior region; as well as A plurality of panels, said plurality of panels being at least partially disposed in the internal region and connected to the frame, said plurality of panels comprising: A first panel includes a first side and a second side opposite to the first side, a first surface and a second surface opposite to the first surface, the first surface defining a plurality of valleys and a plurality of planar regions between the plurality of valleys, the second surface defining a plurality of ridges complementary to the plurality of valleys, the plurality of valleys and the plurality of ridges of the first panel cooperating to define a first corrugated portion extending in a first direction between the first side and the second side, and A second panel, coupled to the first panel, includes a third surface and a fourth surface opposite to the third surface. The third surface defines a plurality of valleys and a plurality of planar regions between the valleys, and the fourth surface defines a plurality of ridges complementary to the valleys. The valleys and ridges of the second panel cooperate to define a second corrugated portion extending along the first direction. The second surface of the first panel faces the fourth surface of the second panel, such that a plurality of ridges of the first panel are aligned with a plurality of ridges of the second panel, and a plurality of cavities are defined between a plurality of planar portions of the first panel and a plurality of planar portions of the second panel. The thermal barrier material is at least partially disposed in the plurality of cavities. The plurality of panels further includes a third panel and a fourth panel connected to the third panel, wherein the third panel and the fourth panel are at least partially disposed in the internal region and connected to the frame, and The first and second panels cooperate to define a cover, the third and fourth panels cooperate to define a base plate, and the cover and the base plate are spaced apart and cooperate with the frame to define an internal compartment for housing an electrochemical device.

2. The structural component according to claim 1, wherein, The first corrugated portion extends continuously between the first side and the second side.

3. The structural component according to claim 1, wherein, The structural components are configured to support external loads greater than or equal to 400 kN.

4. The structural assembly of claim 1, wherein each of the plurality of panels has an average thickness greater than or equal to 0.5 mm and less than or equal to 5 mm.

5. The structural component according to claim 1, wherein, The first corrugated portion includes: Valley width greater than or equal to 5 mm and less than or equal to 250 mm, The width of a planar region is greater than or equal to 5 mm and less than or equal to 250 mm. Angles greater than or equal to 110 degrees and less than or equal to 160 degrees.

6. The structural component of claim 1 further includes a first sealant material, wherein the first sealant material is at least partially disposed between the second panel and the frame.

7. The structural component of claim 6 further includes a second sealant material, wherein the second sealant material is at least partially disposed between the first panel and the plate.

8. The structural component of claim 6 further comprises a metallic material, wherein the metallic material is at least partially disposed between the first panel and the second panel.

9. The structural component of claim 1, wherein the plurality of panels comprises high-strength steel, high-strength aluminum, or both high-strength steel and high-strength aluminum.

10. The structural component of claim 1, wherein the first panel is configured as a vehicle floor.

11. An electrochemical device assembly comprising: The structural component according to claim 1; as well as An electrochemical device, wherein the electrochemical device is disposed in the internal compartment.

12. A structural component, comprising: A frame, the frame including walls that at least partially define an interior region; A plurality of panels, at least partially disposed in the internal region and connected to the frame, the plurality of panels including a first side and a second side opposite to the first side, the first side and the second side extending longitudinally in a first direction, the plurality of panels including: A first panel includes a first side and a second side opposite to the first side, a first surface and a second surface opposite to the first surface, the first surface defining a plurality of valleys and a plurality of planar regions between the plurality of valleys, the second surface defining a plurality of ridges complementary to the plurality of valleys, the plurality of valleys and the plurality of ridges of the first panel cooperating to define a first corrugated portion extending in a first direction between the first side and the second side, and A second panel is connected to the first panel, the second panel including a third surface and a fourth surface opposite to the third surface, the third surface defining a plurality of valleys and a plurality of planar regions between the plurality of valleys, and the fourth surface defining a plurality of ridges complementary to the plurality of valleys, the plurality of valleys and the plurality of ridges of the second panel cooperating to define a second corrugated portion extending along the first direction. The second surface of the first panel faces the fourth surface of the second panel, such that a plurality of ridges of the first panel are aligned with a plurality of ridges of the second panel, and a plurality of cavities are defined between a plurality of planar portions of the first panel and a plurality of planar portions of the second panel. The thermal barrier material is at least partially disposed in the plurality of cavities. The plurality of panels further includes a third panel and a fourth panel connected to the third panel, wherein the third panel and the fourth panel are at least partially disposed in the internal region and connected to the frame, and The first panel and the second panel cooperate to define a cover, the third panel and the fourth panel cooperate to define a base plate, and the cover and the base plate are spaced apart and cooperate with the frame to define an internal compartment for housing an electrochemical device; A first plate, the first plate comprising a first elongated body extending between a first end and a second end, the first elongated body extending in a first direction; and Multiple fasteners, including: At least a portion of the plurality of panels is disposed at least partially between the first panel and the frame, and The plurality of fasteners are configured to clamp the first plate to the frame.

13. The structural component according to claim 12, wherein: The first plate has an average thickness greater than or equal to 2 mm and less than or equal to 10 mm, and A first portion of the first plate is connected to at least a portion of the plurality of panels, the first portion of the first plate having an average size greater than or equal to 25 mm and less than or equal to 50 mm.

14. The structural component of claim 12, further comprising a second plate and a plurality of fasteners, the second plate including a second elongated body extending between a third end and a fourth end, the second elongated body extending in the first direction, wherein: The first plate is connected to the plurality of panels at the first side. The second plate is connected to the plurality of panels at the second side. At least a portion of the plurality of panels are disposed at least partially between the second panel and the frame, and The second plurality of fasteners are configured to clamp the second plate to the frame.

15. The structural assembly of claim 12, wherein the first plate extends along a length greater than or equal to 70% of the length of the plurality of panels.

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